Diffuser for aircraft heating and air conditioning system

ABSTRACT

A heating and/or air conditioning system comprising a blower for generating an air stream and a heat exchanger unit for heating or cooling the air stream includes a diffuser which is positioned between the blower and the heat exchanger unit and which comprises a plurality of vertically spaced diffuser plates, each of which includes an upstream edge and a downstream edge. The vertical distance between the downstream edges of at least an adjacent pair of diffuser plates is greater than the vertical distance between the upstream edges of the pair of diffuser plates. Thus, the diffuser diffuses the air stream vertically prior to the air stream entering the heat exchanger unit.

This application is based on U.S. Provisional Patent Application No. 61/340,362, which was filed on Mar. 15, 2010.

BACKGROUND OF THE INVENTION

The present invention relates to an air diffuser for a heating and air conditioning system. More particularly, the invention relates to a diffuser for an aircraft heating and air conditioning system.

Conventional heating and air conditioning (“HVAC”) systems include a blower for generating a stream of air and a heat exchanger unit for heating or cooling the air. The efficiency of an HVAC system is affected by the degree of heat transfer between the air stream and the heat exchanger unit. The more evenly and uniformly the air can be made to flow over the entire surface of the heat exchanger unit, the better will be the heat transfer between the air and the heat exchanger unit.

In conventional HVAC systems, the air stream exiting the blower often does not flow uniformly over the heat exchanger unit. Instead, the air stream tends to flow mainly through only a portion of the surface of the heat exchanger unit. Consequently, temperature differentials are created within the overall air stream which tend to reduce the efficiency of the system.

SUMMARY OF THE INVENTION

In accordance with the present invention, these and other limitations in the prior art are addressed by providing a novel diffuser for a heating and/or air conditioning system which includes a blower for generating an air stream and a heat exchanger unit for heating or cooling the air stream. The diffuser is positioned between the blower and the heat exchanger unit and comprises a plurality of vertically spaced diffuser plates, each of which includes an upstream edge and a downstream edge. The vertical distance between the downstream edges of at least an adjacent pair of diffuser plates is greater than the vertical distance between the upstream edges of said pair of diffuser plates. Thus, the diffuser diffuses the air stream vertically prior to the air stream entering the heat exchanger unit.

In accordance with one embodiment of the invention, the diffuser further comprises at least two horizontally spaced support brackets, each of which extends generally vertically through the diffuser plates and includes an upstream end and a downstream end. The horizontal distance between the downstream ends of the support brackets is greater than the horizontal distance between the upstream ends of the support brackets. Thus, the diffuser diffuses the air stream both vertically and horizontally prior to the air stream entering the heat exchanger unit.

These and other objects and advantages of the present invention will be made apparent from the following detailed description, with reference to the accompanying drawings. In the drawings, the same reference numbers may be used to denote similar components in the various embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is cross sectional representation of an exemplary aircraft heating and air conditioning system incorporating the diffuser of the present invention;

FIG. 2 is a perspective view of the upper diffuser sub component of the diffuser shown in FIG. 1;

FIG. 3 is a front elevation view of the upper diffuser sub shown in FIG. 1;

FIG. 4 is a side elevation view of the upper diffuser sub shown in FIG. 1;

FIG. 5 is a front elevation view of the upper flange bracket component of the upper diffuser sub shown in FIG. 1;

FIGS. 6A and 6B are top plan and side elevation views, respectively, of the top diffuser plate component of the upper diffuser sub shown in FIG. 1;

FIGS. 7A and 7B are top plan and side elevation views, respectively, of the middle diffuser plate component of the upper diffuser sub shown in FIG. 1;

FIGS. 8A and 8B are top plan and side elevation views, respectively, of the bottom diffuser plate component of the upper diffuser sub shown in FIG. 1;

FIG. 9 is a perspective view of the lower diffuser sub component of the diffuser shown in FIG. 1;

FIG. 10 is a front elevation view of the lower diffuser sub shown in FIG. 1;

FIG. 11 is a side elevation view of the lower diffuser sub shown in FIG. 1;

FIG. 12 is a front elevation view of the lower flange bracket component of the lower diffuser sub shown in FIG. 1;

FIGS. 13A and 13B are top plan and side elevation views, respectively, of the top diffuser plate component of the lower diffuser sub shown in FIG. 1;

FIGS. 14A and 14B are top plan and side elevation views, respectively, of the middle diffuser plate component of the lower diffuser sub shown in FIG. 1;

FIGS. 15A and 15B are top plan and side elevation views, respectively, of the bottom diffuser plate component of the lower diffuser sub shown in FIG. 1;

FIG. 16 is a perspective view of a second embodiment of an aircraft heating and air conditioning system incorporating the diffuser of the present invention;

FIG. 17 is a partial side elevation view of the heating and air conditioning system taken along line A-A of FIG. 16;

FIG. 18 is a front sectional view of the heating and air conditioning system taken along line B-B of FIG. 16;

FIG. 19 is a partial perspective view of the blower and diffuser assembly of the heating and air conditioning system shown in FIG. 16;

FIG. 20 is a side elevation view of the blower and diffuser assembly shown in FIG. 19, with a portion of the blower throat removed to better show the diffuser component; and

FIG. 21 is a top plan view of the blower and diffuser assembly shown in FIG. 19, with a portion of the blower throat removed to better show the diffuser component.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, the diffuser of the present invention, generally 10, is shown installed in an exemplary aircraft heating and air conditioning system 12. The heating and air conditioning system 12 comprises a diverging inlet plenum 14, a blower 16 which is connected to the inlet of the inlet plenum, a heat exchanger unit 18 which is connected to the outlet of the inlet plenum, a converging outlet plenum 20 which is connected to the outlet of the heat exchanger unit, and an air supply conduit 22 which is connected to the outlet of the outlet plenum.

In operation of the heating and air conditioning system 12, the blower 16 generates a flow of air which is directed into the inlet plenum 14 and over the diffuser 10. After exiting the diffuser 10, the air flows through the heat exchanger unit 18, where it either absorbs heat from a relatively high temperature heat source or dissipates heat into a relatively low temperature heat sink, depending on whether the heating and air conditioning system 12 is operating as a heater or a cooler, respectively. After the air passes through the heat exchanger unit 18, it converges in the outlet plenum 20 and enters the air supply conduit 22, which is typically connected to an aircraft in order to heat or cool the cabin as the aircraft is parked on the tarmac.

In accordance with the present invention, the diffuser 10 serves to spread the air flow both vertically and horizontally over a large portion of the cross sectional area of the heat exchanger unit 18 in order to improve the efficiency of the transfer of heat between the air and the heat exchanger unit.

The diffuser 10 may be constructed as a single unit. However, in order to simplify assembly of the diffuser 10 with the heating and air conditioning system 12, the diffuser may be divided into an upper sub 24 and a lower sub 26.

Referring to FIGS. 2 through 5, the upper sub 24 includes an upper flange bracket 28 in which top, middle and bottom diffuser plates 30, 32 and 34 are mounted. As shown most clearly in FIG. 5, the upper flange bracket 28 comprises a generally C-shaped body 36 in which opposing pairs of top, middle and bottom slots 38, 40 and 42 are formed. The downstream side edges of the top, middle and bottom diffuser plates 30, 32, 34 are received and preferably welded in the top, middle and bottom slots 38, 40, 42, respectively, in order to connect the diffuser plates to the upper flange bracket 28. The body 36 also includes a number of holes 44 which align with corresponding holes in the adjacent flange of the inlet plenum 14 order to secure the upper sub 24 to the heating and air conditioning unit system.

An embodiment of the top diffuser plate 30 is shown with its representative dimensions in FIGS. 6A and 6B. Likewise, embodiments of the middle and bottom diffuser plates 32, 34 are shown with their representative dimensions in FIGS. 7A and 7B and FIGS. 8A and 8B, respectively. As shown in these figures, when viewed together with FIG. 4, each of the diffuser plates 30, 32, 34 comprises a generally flat body 46 which extends from the upstream edge of the diffuser plate to approximately the upper flange bracket 28, and a lip 48 which angles downwardly from the downstream edge of the body to the downstream edge of the diffuser plate.

The upper sub 24 may also include two transverse support brackets 50 and two transverse stiffener brackets 52. As shown most clearly in FIGS. 2, 4 and 6-8, each support bracket 50 is received and secured in a corresponding slot 54 which is formed in the body 46 of each diffuser plate 30, 32, 34. Similarly, each stiffener bracket 52 is received and secured in a corresponding elongated aperture 56 which is formed in the body 54 of each diffuser plate 30, 32, 34 proximate the upstream edge of the diffuser plates.

As shown most clearly in FIG. 4, the diffuser plates 30, 32, 34 are mounted and connected together such that the vertical distance between adjacent diffuser plates at their downstream edges, or at least at the upper flange bracket 28, is greater than the vertical distance between adjacent diffuser plates at their upstream edges. This configuration serves to diffuse the air stream vertically. Also, as a result of the slots 54 being oriented at an angle relative to the longitudinal centerlines of the diffuser plates 30, 32, 34 as shown in FIGS. 6-8, the support brackets 50 are similarly oriented such that the distance between their downstream ends is greater than the distance between their upstream ends. Consequently, the support brackets 50 will act to diffuse the air stream horizontally.

The structure of the lower diffuser sub 26 is very similar to that of the upper diffuser sub 24. Referring briefly to FIGS. 9-11, the lower diffuser sub 26 comprises a lower flange bracket 58 in which top, middle and bottom diffuser plates 60, 62 and 64 are mounted. An embodiment of the lower flange bracket with its representative dimensions is shown in FIG. 12. Embodiments of the top, middle and bottom diffuser plates 60, 62, 64 with their corresponding representative dimensions are shown in FIGS. 13A and 13B, FIGS. 14A and 14B, and FIGS. 15A and 15B, respectively.

As with the upper diffuser sub 24, the lower diffuser sub 26 includes two support brackets 66 which are similar to the support brackets 50 and two stiffener brackets 68 which are similar to the stiffener brackets 52. These support and stiffener brackets 66, 68 are received in and connected to corresponding slots and apertures in the diffuser plates 60, 62 and 64 in a manner similar to the support and stiffener brackets 50, 52.

In order to assemble the diffuser 10 with the heating and air conditioning unit 12, the lower diffuser sub 26 is inserted into the inlet plenum 14 and bolted to the downstream flange 70 of the inlet plenum (FIG. 1). The upper diffuser sub 24 is then inserted into the inlet plenum 14 above the lower diffuser sub 26 and bolted to the downstream flange 70. In order to facilitate the assembly of the upper diffuser sub 24 with the lower diffuser sub 26, each of the support brackets 50 of the upstream diffuser sub may be provided with a transverse lower foot 72 (FIG. 2), each of the support brackets 66 of the lower diffuser sub may be provided with a transverse upper foot 74 (FIG. 9), and these feet may be secured together after the upper diffuser sub is positioned on the lower diffuser sub.

A second embodiment of an aircraft heating and air conditioning system in which the diffuser 10 may be incorporated is illustrated in FIGS. 16 through 18. The heating and air conditioning system of this embodiment, which is indicated generally by reference number 100, includes a blower 102 for generating a flow of air to either heat or cool an aircraft. The blower 102 comprises a diverging throat 104 having a generally circular outlet flange 106. The outlet flange 106 is connected to an upstream end wall 108 of a diverging inlet plenum 110. The outlet of the inlet plenum 110 is connected to one side of a heat exchanger unit 112, the opposite side of which is connected to a converging outlet plenum 114. The downstream end of the outlet plenum 114 comprises an outlet port 116 to which an air supply conduit (not shown) may be connected. Although not required, the components of the heating and air conditioning system 100 may be mounted on a base structure 118.

In this embodiment of the invention, the diffuser 10 is mounted in the throat 104 of the blower 102. Referring also to FIGS. 19 through 21, the upstream ends of the upper and lower subs 24, 26 are inserted into the throat 104 to position the upper and lower flange brackets 28, 58 against the upstream end wall 108 of the inlet plenum 110. A number of bolts 120 extend through corresponding aligned holes in the upper and lower flange brackets 28, 58, the upstream end wall 108 and the flange 106 to thereby secure the diffuser 10 to the blower 102.

In operation of the heating and air conditioning system 100, the blower 102 generates a flow of air which is directed into the throat 104 and over the diffuser 10. As the air passes over the diffuser 10, the upper and lower diffuser plates 30-34, 60-64 spread the air stream vertically and the upper and lower support brackets 50, 66 spread the air stream horizontally. The air stream then continues to diffuse both vertically and horizontally as it passes through the inlet plenum 110. After exiting the inlet plenum 110, the air flows through the heat exchanger unit 112, where it either absorbs heat from a relatively high temperature heat source or dissipates heat into a relatively low temperature heat sink, depending on whether the heating and air conditioning system 100 is operating as a heater or a cooler, respectively. After the air passes through the heat exchanger unit 112, it converges in the outlet plenum 114 and exits the heating and air conditioning system 100 through the outlet port 116.

It should be recognized that, while the present invention has been described in relation to the preferred embodiments thereof, those skilled in the art may develop a wide variation of structural and operational details without departing from the principles of the invention. Therefore, the appended claims are to be construed to cover all equivalents falling within the true scope and spirit of the invention. 

1. In combination with a heating and/or air conditioning system which includes a blower for generating an air stream and a heat exchanger unit for heating or cooling the air stream, the improvement comprising a diffuser which is positioned between the blower and the heat exchanger unit and which comprises: a plurality of vertically spaced diffuser plates, each of which includes an upstream edge and a downstream edge; wherein the vertical distance between the downstream edges of at least an adjacent pair of diffuser plates is greater than the vertical distance between the upstream edges of said pair of diffuser plates; whereby the diffuser diffuses the air stream vertically prior to the air stream entering the heat exchanger unit.
 2. The combination of claim 1, wherein the diffuser further comprises: at least two horizontally spaced support brackets, each of which extends generally vertically through the diffuser plates and includes an upstream end and a downstream end; wherein the horizontal distance between the downstream ends of the support brackets is greater than the horizontal distance between the upstream ends of the support brackets; whereby the diffuser diffuses the air stream both vertically and horizontally prior to the air stream entering the heat exchanger unit.
 3. The combination of claim 1, wherein each diffuser plate comprises a generally flat body and a lip which extends from a downstream edge of the body.
 4. The combination of claim 3, wherein each lip comprises a generally flat first portion which extends from the downstream edge of the body and a generally flat second portion which extends from a downstream edge of the first portion.
 5. The combination of claim 4, wherein the first portion of each lip extends downwardly at a first angle relative to the body and the second portion of each lip extends downwardly at a second angle relative to the first portion.
 6. The combination of claim 5, wherein for each diffuser plate, the first angle is greater than or equal to the second angle.
 7. The combination of claim 4, wherein the plurality of diffuser plates comprises at least a first diffuser plate, a second diffuser plate which is positioned below the first diffuser plate and a third diffuser plate which is positioned below the second diffuser plate, and wherein the first angle of the first diffuser plate is less than the first angle of the second diffuser plate and the first angle of the second diffuser plate is less than the first angle of the third diffuser plate.
 8. The combination of claim 7, wherein the second angle of the first diffuser plate is less than the second angle of the second diffuser plate and the second angle of the second diffuser plate is less than the second angle of the third diffuser plate.
 9. The combination of claim 7, wherein the plurality of diffuser plates also comprises at least a fourth diffuser plate which is positioned below the third diffuser plate, a fifth diffuser plate which is positioned below the fourth diffuser plate and a sixth diffuser plate which is positioned below the fifth diffuser plate, and wherein the first angle of the fourth diffuser plate is less than the first angle of the fifth diffuser plate and the first angle of the fifth diffuser plate is greater than the first angle of the sixth diffuser plate.
 10. The combination of claim 9, wherein the second angle of the fourth diffuser plate is less than the second angle of the fifth diffuser plate and the second angle of the fifth diffuser plate is greater than the second angle of the sixth diffuser plate.
 11. The combination of claim 1, wherein the plurality of diffuser plates comprises at least a first diffuser plate, a second diffuser plate which is positioned below the first diffuser plate and a third diffuser plate which is positioned below the second diffuser plate, and wherein the vertical distance between the downstream edges of the first and second diffuser plates is greater than the vertical distance between the upstream edges of the first and second diffuser plates and the vertical distance between the downstream edges of the second and third diffuser plates is greater than the vertical distance between the upstream edges of the second and third diffuser plates.
 12. The combination of claim 11, wherein the plurality of diffuser plates also comprises at least a fourth diffuser plate which is positioned below the third diffuser plate, a fifth diffuser plate which is positioned below the fourth diffuser plate and a sixth diffuser plate which is positioned below the fifth diffuser plate, and wherein the vertical distance between the downstream edges of the fourth and fifth diffuser plates is greater than the vertical distance between the upstream edges of the fourth and fifth diffuser plates and the vertical distance between the downstream edges of the fifth and sixth diffuser plates is greater than the vertical distance between the upstream edges of the fifth and sixth diffuser plates.
 13. The combination of claim 1, further comprising at least one flange bracket to which the diffuser plates are connected, the flange bracket being connected to a portion of the heating and air conditioning unit to thereby secure the diffuser to the heating and air conditioning unit.
 14. The combination of claim 12, wherein the blower comprises a throat and the flange bracket is connected to the throat.
 15. The combination of claim 13, wherein the diffuser plates extend at least partially into the throat.
 16. The combination of claim 13, wherein the at least one flange bracket comprises at least first and second flange brackets.
 17. The combination of claim 16, wherein the plurality of diffuser plates comprises at least a first diffuser plate which is connected to the first flange bracket, a second diffuser plate which is connected to the first flange bracket below the first diffuser plate, and a third diffuser plate which is connected to the first flange bracket below the second diffuser plate.
 18. The combination of claim 17, wherein the diffuser further comprises: at least two horizontally spaced support brackets, each of which extends generally vertically through the first, second and third diffuser plates and includes an upstream end and a downstream end; wherein the horizontal distance between the downstream ends of the support brackets is greater than the horizontal distance between the upstream ends of the support brackets.
 19. The combination of claim 17, wherein the plurality of diffuser plates also comprises at least a fourth diffuser plate which is connected to the second flange bracket, a fifth diffuser plate which is connected to the second flange bracket below the fourth diffuser plate, and a sixth diffuser plate which is connected to the second flange bracket below the fifth diffuser plate.
 20. The combination of claim 19, wherein the diffuser further comprises: at least two horizontally spaced support brackets, each of which extends generally vertically through the fourth, fifth and sixth diffuser plates and includes an upstream end and a downstream end; wherein the horizontal distance between the downstream ends of the support brackets is greater than the horizontal distance between the upstream ends of the support brackets. 